US5718967A — Coated plastic substrate

Claim 1

Independent Claim 106 words

A laminate which comprises: a) a plastic substrate having a surface; b) an adhesion promoter layer which is a first plasma polymerized organosilicon compound deposited on the surface of the substrate at a power level in the range of about 5×10 7 J/kg to about 5×10 9 J/kg, and in the substantial absence of oxygen; and c) a protective coating layer which is a second plasma polymerized organosilicon compound deposited on the surface of the adhesion layer at a power density from about 10 6 J/kg to about 10 8 J/kg, and in the presence of a higher level of oxygen than used in step (b).

Claim 2

Dependent Claim 106 words

A laminate which comprises: a) a plastic substrate having a surface; b) an adhesion promoter layer which is a first plasma polymerized organosilicon compound deposited on the surface of the substrate at a power level in the range of about 5×10 7 J/kg to about 5×10 9 J/kg, and in the substantial absence of oxygen; and c) a protective coating layer which is a second plasma polymerized organosilicon compound deposited on the surface of the adhesion layer at a power density from about 10 6 J/kg to about 10 8 J/kg, and in the presence of a higher level of oxygen than used in step (b).

Claim 3

Dependent Claim 61 words

The laminate of claim 1 which further comprises an SiO x layer which is a plasma polymerized third organosilicon compound deposited on the surface of the layer of the protective coating layer, in the presence of a stoichiometric excess of oxygen, and at a power density of at least about twice the power density used to form the protective coating layer.

Claim 4

Dependent Claim 20 words

The laminate of claim 2 which further comprises alternating layers of the protective coating layer and the SiO x layer.

Claim 5

Dependent Claim 49 words

The laminate of claim 2 wherein the first, the second, and the third organosilicon polymers that are plasma polymerized are each independently selected from the group consisting of dimethoxydimethylsilane, methyltrimethoxysilane, tetramethoxysilane, methyltriethoxysilane, diethoxydimethylsilane, methyltriethoxysilane, triethoxyvinylsilane, tetraethoxysilane, dimethoxymethylphenylsilane, phenyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-methacryloxypropyltrimethoxysilane, diethoxymethylphenylsilane, tris(2-methoxyethoxy)vinylsilane, phenyltriethoxysilane, dimethoxydiphenylsilane, tetramethyldisiloxane, hexamethyldisiloxane, hexamethylsilazane, and tetramethylsilazane.

Claim 6

Dependent Claim 21 words

The laminate of claim 4 wherein the first, the second, and the third organosilicon polymers that are plasma polymerized are tetramethyldisiloxane.

Claim 7

Dependent Claim 28 words

The laminate of claim 2 wherein the substrate is a carbonate polymer which comprises repeat units of a reaction product of a carbonate precursor with an aromatic diol.

Claim 8

Dependent Claim 28 words

The laminate of claim 6 wherein the aromatic diol comprises resorcinol, catechol, hydroquinone, a dihydroxynaphthalene, a dihydroxyanthracene, a bis(hydroxyaryl) fluorene, a dihydroxyphenanthrene, a dihydroxybiphenyl, or a bis(hydroxyphenyl) propane.

Claim 9

Dependent Claim 17 words

The laminate of claim 7 wherein the carbonate polymer comprises repeat units of 9,9-bis(4-hydroxyphenyl)fluorene and bisphenol A.

Claim 10

Dependent Claim 24 words

The laminate of claim 8 wherein the ratio of the repeat units of 9,9-bis(4-hydroxyphenyl)fluorene and bisphenol A is from about 40:60 to about 70:30.

Claim 11

Dependent Claim 48 words

The laminate of claim 1 wherein the T g of the substrate is in the range of from about 180° C. to about 240° C., and the SOC of the laminate is in the range of from about -1000 to about 1000 Brewsters, which laminate is optically clear.

Claim 12

Dependent Claim 272 words

A laminate which comprises: a) a plastic substrate having a surface and a thickness of not less than about 0.1 mm and not more than about 10 mm; b) an adhesion promoter layer which is a plasma polymerized tetramethyldisiloxane deposited on the surface of the substrate at a power level in the range of about 5×10 7 J/kg to about 5×10 9 J/kg and in the substantial absence of oxygen, which adhesion promoter has a thickness of not less than about 1000 Å and not more than 2000 Å; c) a protective coating layer which is a plasma polymerized tetramethyldisiloxane deposited on the surface of the adhesion promoter layer at a power density from about 10 6 J/kg to about 10 8 J/kg in the presence of a sufficient stoichiometric excess of oxygen with respect to tetramethyldisiloxane to form an organosilicon compound having the formula SiO 1 .8-2.4 C 0 .3-1.0 and H 0 .7-4.0 that contains trapped water and at least one of the following functional groups: --Si--O--Si--, --Si--CH 2 --, --Si--H, or --Si--OH; wherein the thickness of the protective coating layer is not less than about 0.1 micron and not greater than about 2 microns; and d) an SiO x layer which is a layer of a plasma polymerized tetramethyldisiloxane deposited on the surface of the protective coating layer, in the presence of a stoichiometric excess of oxygen, and at a power density of at least four times the power density used to form the protective coating layer, wherein the SiO x layer has a thickness of not less than about 0.05 micron and not more than about 1 micron.

Claim 13

Dependent Claim 272 words

A laminate which comprises: a) a plastic substrate having a surface and a thickness of not less than about 0.1 mm and not more than about 10 mm; b) an adhesion promoter layer which is a plasma polymerized tetramethyldisiloxane deposited on the surface of the substrate at a power level in the range of about 5×10 7 J/kg to about 5×10 9 J/kg and in the substantial absence of oxygen, which adhesion promoter has a thickness of not less than about 1000 Å and not more than 2000 Å; c) a protective coating layer which is a plasma polymerized tetramethyldisiloxane deposited on the surface of the adhesion promoter layer at a power density from about 10 6 J/kg to about 10 8 J/kg in the presence of a sufficient stoichiometric excess of oxygen with respect to tetramethyldisiloxane to form an organosilicon compound having the formula SiO 1 .8-2.4 C 0 .3-1.0 and H 0 .7-4.0 that contains trapped water and at least one of the following functional groups: --Si--O--Si--, --Si--CH 2 --, --Si--H, or --Si--OH; wherein the thickness of the protective coating layer is not less than about 0.1 micron and not greater than about 2 microns; and d) an SiO x layer which is a layer of a plasma polymerized tetramethyldisiloxane deposited on the surface of the protective coating layer, in the presence of a stoichiometric excess of oxygen, and at a power density of at least four times the power density used to form the protective coating layer, wherein the SiO x layer has a thickness of not less than about 0.05 micron and not more than about 1 micron.

Claim 14

Dependent Claim 55 words

A laminate which comprises: a) a plastic substrate having a surface; and b) an adhesion promoter layer which is a plasma polymerized organosilicon compound deposited on the surface of the substrate at a power level in the range of about 5×10 7 J/kg to about 5×10 9 J/kg, and in the substantial absence of oxygen.

Claim 15

Dependent Claim 55 words

A laminate which comprises: a) a plastic substrate having a surface; and b) an adhesion promoter layer which is a plasma polymerized organosilicon compound deposited on the surface of the substrate at a power level in the range of about 5×10 7 J/kg to about 5×10 9 J/kg, and in the substantial absence of oxygen.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2001-02-16	2001-08-18	2002-02-17	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2005-02-16	2005-08-18	2006-02-17	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2009-02-16	2009-08-18	2010-02-17	$7700.00	Window Closed / Lapsed

Coated plastic substrate

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